Highly microporous carbon

ABSTRACT

A highly microporous activated carbon is disclosed which is prepared by activation of an active carbon precursor material with a potassium hydroxide solution, pre-drying the blend to below 25% moisture content, activating this blend at from about 650° to about 1100° C., and acid washing and drying the microporous activated carbon product and which is characterized by greater than 50% of its total pore volume comprising pores of from above 8 Å to 20 Å in width and greater than 70% of its total pore volume comprising pores of less than 20 Å in width and greater than 95% of its total pore volume comprising pores of less than 50 Å in width.

This application is a continuation-in-part of U.S. patent applicationSer. No. 08/143,551, filed Oct. 25, 1993, now allowed, U.S. Pat. No.5,416,056.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention is directed to the improved production ofactivated carbon. More particularly, it is directed to the production ofhighly microporous activated carbon. Specifically, the present inventionis directed to the production of highly microporous activated carbonfrom an activated carbon precursor by a subsequent chemical activationprocess employing potassium hydroxide. One use of such activated carbonis in the adsorption of gaseous hydrocarbon fuels, including naturalgas.

(2) Description of the Prior Art

Practical storage of gaseous hydrocarbon fuels, such as natural gaswhich is comprised primarily of methane, for such uses as a vehicle fueland the like involves portable containerization of the gas. Natural gas,in particular, is a leading contender for use as an alternative fuel forautomobiles, particularly in areas designated as "zero emmision" zonesunder the 1990 Clean Air Act. The majority of natural gas vehiclesoperating in the United States use compressed natural gas at pressuresof up to 3600 psi. However, low pressure storage systems are beingdeveloped in which natural gas is contained in storage containers packedwith adsorbent material to achieve near-liquid methane density. Thestorage containers may be formable or nonformable tanks, cylinders, orother closed vessels. Economic evaluations by the natural gas industryindicate that adsorbed natural gas (ANG) would be comparableeconomically with compressed natural gas (CNG) at a deliverable gascapacity of 150 volumes of gas per container (cylinder) volume (v/v) ata storage pressure of 500 psi (measured at 25° C.).

Natural gas, which is primarily methane, is adsorbed in pores and onsurfaces of the adsorbent medium. Under such conditions, the adsorbedgas assumes properties not unlike those of its liquid state. Typicaladsorbents are solids with pores and fissures throughout theirstructure. Methane molecules preferentially adsorb in pores having adiameter of about 10-15 Angstroms (Å). The carbon material of thepresent invention may also be suitable for storage of other gases of asimilar molecular size.

Active carbon long has been used for removal of impurities and recoveryof useful substances from liquids and gases because of its highadsorptive capacity. Generally, "activation" refers to any of thevarious processes by which the pore structure is enhanced. Typicalcommercial activated carbon products exhibit a surface area (as measuredby nitrogen adsorption as used in the BET model) of at least 300 m² /g.For the purposes of this disclosure, the terms "active carbon" and"activated carbon" are used interchangeably. Typical activationprocesses involve treatment of carbon sources--such as resin wastes,coal, coal coke, petroleum coke, lignites, polymeric materials, andlignocellulosic materials including pulp and paper, residues from pulpproduction, wood (like wood chips, sawdust, and wood flour), nut shell(like almond shell and coconut shell), kernel, and fruit pits (likeolive and cherry stones)--either thermally (with an oxidizing gas) orchemically (usually with phosphoric acid or metal salts). Such activatedcarbons maintain the original macrostructure of the starting materialand, therefore, a similar pore distribution of micropores of less than20 Å in width, mesopores of 20 Å to 500 Å (divided between smallmesopores of 20 Å to less than 50 Å in width and large mesopores of 50 Åto 500 Å in width), and macropores of greater than 500 Å in width.

As the surface area of an active carbon is directly proportional to thecarbon's microporosity and since the methane adsorption capacity of anactive carbon is enhanced by increasing its volume of micropores (lessthan 20 Å in width) and small mesopores (20-50 Å in width), as apercentage of total pore volume, activation methods are sought which arepore size specific. In particular, micropores in the range of from above8 Å to about 20 Å are suitable for adsorption of methane. Moreparticularly, pore sizes of from about 10 Å to about 20 Å in width arepreferred for methane adsorption. Most preferred are pore sizes of fromabout 10 Å to about 15 Å. Therefore, carbon materials are desirablewhich are comprised of a high volume (e.g., greater than 50%) of poresless than 16 Å in width as a percentage of total pore volume. Suchmaterials which are comprised of a higher volume (e.g., greater than80%) of pores less than 20 Å in width as a percentage of total porevolume also are desirable. Also desirable are such materials comprisedof an extremely high volume (e.g., greater than 95%) of pores less than50 Å in width as a percentage of total pore volume.

Citing disclosures of potassium hydroxide (KOH) activation of coal inU.S. Pat. Nos. 3,764,561 and 4,082,694, the patentees of U.S. Pat. No.4,769,359 teach the production of active carbon which enables highadsorption of gases per unit volume by treating coal with a liquidmixture comprising KOH and sodium hydroxide (NaOH) and subsequentlycarbonizing at 500°-800° C. A method of producing activated carbon witha large surface area and a low sulfur content also is taught in U.S.Pat. No. 5,064,805 by mixing coconut shell char with melted potassiumhydroxide hydrate at a temperature sufficiently high to causeactivation. Also, U.S. Pat. No. 4,082,694 teaches solid KOH activationof specific carbonaceous feeds including coal, coal coke, and petroleumcoke to produce cage-like microporous structures particularly useful forwater purification.

Chemical activation of wood-based carbon with phosphoric acid (H₃ PO₄)is disclosed in U.S. Patent No. Re. 31,093 to improve the carbon'sdecolorizing and gas adsorbing abilities. Also, U.S. Pat. No. 5,162,286teaches phosphoric acid activation of wood-based material which isparticularly dense and which containing a relatively high (30%) lignincontent, such as nut shell, fruit stone, and kernel. Zinc chloride(ZnCl₂) also is a common chemical activation agent. Phosphoric acidactivation of lignocellulose material also is taught in U.S. Pat. No.5,204,310 as a step in preparing carbons of high activity and highdensity.

Also, U.S. Pat. No. 4,769,359 teaches producing active carbon bytreating coal cokes and chars, brown coals or lignites with a mixture ofNaOH and KOH and heating to at least 500° C. in and inert atmosphere.U.S. Pat. No. 5,102,855 discloses making high surface area activatedcarbon by treating newspapers and cotton linters with phosphoric acid orammonium phosphate. Coal-type pitch is used as a precursor to prepareactive carbon by treating with NaOH and/or KOH in U.S. Pat. No.5,143,889. Finally, U.S. Pat. No. 5,292,706 teaches storing natural gasunder pressures of 1400 to 4500 kPa using a carbon sieve adsorbent madeby impregnating a polymer precursor of the carbon molecular sieve withadditional monomers and polymerizing the monomers before carbonizing theprecursor.

None of these activated carbons, however, achieve the desired objectiveof providing 150 v/v of deliverable gas capacity at 500 psi. Such acarbon is taught, in U.S. patent application Ser. No. 08/143,551, to beproduced by a two-step chemical activation process. A lignocellulosicmaterial was first activated with phosphoric acid and then activatedwith potassium hydroxide under thermal conditions. While permittingsmall scale, laboratory production of the desired carbon material, thedisclosed process has several disadvantages which preclude commercialproduction to avail the product to public use. The large volume of wetcarbon material, upon blending with activating agent solution, presentsmaterial handling problems. Also, the batch nature of the process,combined with the requirement of a relatively long duration of thermaltreatment with gradual incremental temperature increases, precludesefficient, economical production rates. In addition, it was discoveredthat the disclosed process leaves residual potassium which, along withcalcium adsorbed from the wash water, adversely impacted the highlymicroporous carbon's performance.

Therefore, the objective of this invention is to provide an improvedprocess for manufacturing a highly microporous activated carbon capableof meeting the industry target for a deliverable capacity of a gaseoushydrocarbon fuel stored on activated carbon. It is also an objective ofthis invention to provide a highly microporous active carbon materialthat is specific for storage of methane in natural gas to provide adeliverable capacity of 150 v/v of the methane at 500 psi (at 25° C.).It is a further objective of this invention to provide a method forstoring natural gas at low pressure using the highly microporousactivated carbon.

SUMMARY OF THE INVENTION

The objectives of this invention are accomplished by an improved processwhereby highly microporous activated carbon products are produced byactivation of an already activated carbon with KOH. The KOH activationcomprises blending the active carbon material with a potassium hydroxidesolution, pre-drying to reduce the blend to below about 25% moisturecontent, activating this blend at from about 650° to about 1100 ° C.,and acid washing and drying the microporous activated carbon. Themicropore volume and pore size distribution of the activated carbon soobtained are such that the products are useful for adsorbed natural gasstorage. Additionally, the adsorption properties of the activated carbonaccording to the present invention permit its use in applications suchas fractionation of hydrocarbons, purification of industrial gases,anti-pollution devices, liquid-phase purification processes in food andchemical industries, water treatment, liquid-phase recovery andseparation, catalysts or catalyst supports, batteries, analysis, andmedicinal uses, among others.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Phosphoric acid is a popular chemical activation/carbonization agent,but at temperatures above about 300° C. polymerization of the acidcreates wide pores that are not useful for methane adsorption. Otherchemical activation agents, such as zinc chloride, do not produce poresof the size particularly favorable for methane adsorption. It is knownfrom the prior art that initial activation of carbonaceous precursorswith alkali appears to produce micropores of the pore size hypothesizedas being favorable for methane adsorption,. i.e., about 11-12 Å width,but necessary pore volume is not produced and product yield is ofteninadequate. The benefit of employing alkali as a subsequent activationagent is to exploit the merits of different activation agents, whileeliminating adverse effects. In the two-stage H₃ PO₄ /KOH activationprocess disclosed in Ser. No. 143,551, wood is blended with phosphoricadd (1st stage) at an acid to wood ratio of from about 0.5:1 to about3:1, preferably from about 1:1 to about 2:1. Next, the blend is heatedat carbonization temperatures, and the acid is removed from the system.The activated product of the first stage then is chemically activatedfurther by blending with potassium hydroxide at a KOH to char ratio ofabout 0.5:1 to 4:1, preferably about 1:1 to 2.5:1, at highertemperatures (2nd stage) to yield a product suitable for natural gasstorage. The first stage carbonization temperature is from about 150° toabout 590° C., and the second stage higher activation temperature isfrom about 650° to about 980° C. After cooling, the highly microporousactive carbon is washed with water to remove residual potassium from thecarbon and dried. Experience with the parent application (S.N. '551)process has proved that removing potassium from the small pores of thecarbon to a residual level of below 1 wt % was very time consuming whenusing only water. It has been discovered that by incorporating an acidwash step, followed by a pH adjustment step (if necessary for specificproduct end uses), the total wash time was reduced significantly, whileobtaining less than 0.1 wt % residual potassium. Other improvements alsohave been discovered which form the present invention.

The disclosure of the parent application (S.N. '551) is incorporated byreference herein.

Significantly, the improved process of the present invention differsfrom that disclosed in the parent application ('551) in that theactivated carbon precursor material for KOH activation does not have tohave been activated by phosphoric acid. In fact, the activated precursorcan be the product of another chemical activation agent or the productof thermal or other activation process. Also, the improved process ofthe present invention differs from that disclosed in the '551 parentapplication in that the activated carbon is not restricted tolignocellulosic material and the second stage activation agent can beselected from alkalies in general. For the purposes of the presentdisclosure, the term "alkali" refers broadly to the hydroxides andcarbonates of alkali metals and alkaline earth metals, as well as thebicarbonate and hydroxide of the radical ammonium and combinationsthereof, but preferably the hydroxides and carbonates of sodium andpotassium and combinations thereof. The activated precursor material forthe alkali activation may also be derived from other thanlignocellulosic material, as noted in an example below.

Nevertheless, the most preferred precursor for the invention process isa wood-based activated carbon such as Westvaco's commercial product,WV-A 1100, which is a product with a pore size distribution tailored tothe capture of evaporative gasoline emissions and produced under H₃ PO₄activation.

Alternatively, other examples of activated carbonaceous materialsuitable for subsequent alkali activation according to the invention arethe high butane working capacity (BWC) carbons (and methods of theirpreparation) reported in U.S. Pat. Nos.: 5,204,310; 5,206,207;5,238,470; and 5,250,491, the disclosures of which are incorporatedherein by reference. Basically, the invention includes a subsequentalkali activation of activated carbon materials.

Alkali Activation

In addition to a broader range of precursor materials and activants, amost significant improvement over the KOH activation step disclosed inS.N. '551 is the provision of continual material throughput with a shortresidence time over the previous time consuming batch thermal activationstage. A granular WV-A 1100 product is blended with a solution of alkaliat a alkali/activated carbon ratio of 0.5:1-5:1 (dry weight basis). Thewet blend material is pre-dried in conventional drying equipment such asa tray drier, a fluidized bed dryer, a rotary kiln drier, or a blenderdrier. Drying is effected in a hot gas atmosphere and preferably in ahot inert atmosphere.

The pre-dried, moist carbon (preferably, ˜10% moisture content) isactivated in a continuous rotary kiln comprising a heated section and acooling section. The heated section is designed to raise the carbontemperature to from about 650°-1100° C. for from 5-40 minutes,preferably 8-15 minutes. The cooling section, preferably with a N₂purge, permits reducing the activated carbon temperature prior towashing.

The cooled activated char, which is alkaline, is washed first with waterto reduce the potassium level, after which the active carbon material iswashed with acid water of a pH of 1.5-5.0 to reduce the potassium levelto less than 0.5%, preferably less than 0.2%, and most preferably lessthan 0.1%. The acid wash is followed by a neutralization cycle with NaOHto bring the pH of the carbon/water suspension up to a pH of 3.0-75,preferably 6.5. Finally, a neutral water wash is employed to rinse thecarbon.

After the rinsed carbon is allowed to drain, it is dried. A multi-shelfcart oven may be employed for drying. More detailed embodiments of theinvention process are set forth in the following examples.

EXAMPLE 1

A product of the first stage-phosphoric acid activation, or granular,10×25 mesh WV-A 1100 product, was treated as stated above. It wasblended with a KOH solution at a KOH/C ratio of 1.8:1 (dry basis) in afluidizing blender/dryer and dried for 28 minutes (to achieve the targetmoisture of 10%, wet basis). Because the dried blend was less tacky(versus the process without pre-drying), material yield across thisprocess step increased from 82 to 98% (db), and the earlier need to washout the blender between batches was eliminated.

Thermal treatment of the pre-dried KOH/C blend was carried out under anitrogen atmosphere in an indirect-fired, continuous pilot rotary kiln.Firing of the lain was maintained throughout the production run, andfeed was continuous with only two interruptions. Kiln rotational speedwas 1.2 rpm, resulting in a residence time of 10 minutes. The nominalfeed rate of dried, alkaline blend was 60 lb/hour. Largely because oflimitations on control of feed screw speed, production rate of(activated) alkaline char varied between about 36 and 46 lb/hour andaveraged 43 lb/hour (db). A total of 6000 lb (db) of KOH/C blend was fedto the activation kiln.

The washing procedure, which extracted potassium salts from the alkalinechar, was carried out in a 220-gallon tank. Each batch of alkaline char(400-500 lb) was washed in about seven hours, which matches activationkiln output at a nominal feed rate of 60 lb/hour. The drying step wascarried out as described previously in a convection drying oven.Properties produced by the process are set forth in the followingtables. Table I shows surface area and pore size distribution data.

                  TABLE I                                                         ______________________________________                                                   SURFACE AREA AND PORE SIZE                                                    DISTRIBUTION OF PRODUCT                                            PRODUCT PROPERTY                                                                           A       B       C     D     Avg                                  ______________________________________                                        Surface Area (m.sup.2 g.sup.-1)                                                            2368    2372    2366  2352  2365                                 Pore Volume (cc/g):                                                           <20Å Width                                                                             0.84    0.84    0.86  0.83  0.84                                 <50Å Width                                                                             1.12    1.12    1.12  1.12  1.12                                 <1000Å Width                                                                           1.15    1.15    1.14  1.14  1.15                                 ______________________________________                                    

The BET nitrogen surface areas of the product averaged 2365 m² g⁻¹.Micropore volume for less than 20 Å pore widths averaged 0.84 cc/g, asdetermined using the BJH method of pore size analysis.

Table II describes the methane adsorption properties of the inventionexample products:

                  TABLE II                                                        ______________________________________                                        METHANE CAPACITY DATA                                                                MWC      MTC    Me.Act  Density                                                                             Retentivity                              Sample (v/v)    (v/v)  (wt %)  (g/cc)                                                                              (%)                                      ______________________________________                                        E      154      174    18.5    0.532 13                                       F      153      173    18.8    0.518 13                                       G      154      174    17.8    0.553 13                                       H      153      175    18.6    0.533 14                                       I      153      172    18.4    0.527 12                                       J      153      174    19.1    0.512 13                                       K      151      171    18.2    0.530 13                                       L      154      174    18.6    0.528 13                                       M       54      174    19.3    0.505 13                                       N      155      173    19.0    0.513 12                                       O      154      173    19.5    0.500 13                                       Average:                                                                             153      173    18.7    0.523 13                                       ______________________________________                                    

The methane capacity data shown in Table II demonstrate that theinvention process can be tightly controlled to produce consistentproduct. The methane working capacity of the product averaged 153 v/v,meeting the target of 150 v/v. Total capacity averaged 173 v/v; weightactivity averaged 18.7 wt %); methane retentivity averaged 13%; andpacked density averaged 0.523 g/cc).

Table III shows the trace metals levels of the highly microporous carbonproducts.

                  TABLE III                                                       ______________________________________                                                      TRACE                                                                         K                                                                             LEVELS                                                                        (wt %)                                                                 Sample K                                                               ______________________________________                                               E      0.01                                                                   F      0.03                                                                   G      0.01                                                                   H      0.01                                                                   I      0.01                                                                   J      0.01                                                                   K      0.01                                                                   L      0.01                                                                   M      0.01                                                                   N      0.01                                                                   O      0.02                                                                   Average:                                                                             0.01                                                            ______________________________________                                    

Residual potassium levels were consistently near 0.01 wt %.

EXAMPLE 2

To substantiate the resultant pore size re-distribution as a result ofinvention treatment of the lignocellulosic material, a sample product ofthe disclosed process was analyzed for pore size distribution by theDensity Functional Theory (DFT) using argon adsorption data, a procedureknown to those skilled in the art. The results of the analysis arereported in Table IV.

                  TABLE IV                                                        ______________________________________                                        Pore Width (Å)*                                                                          % of Total (< size)                                            ______________________________________                                         4.1            0.0                                                            4.4            0.7                                                            5.1           10.4                                                            5.9           15.1                                                            6.8           18.6                                                            8.0           27.6                                                            9.3           37.3                                                           10.0           37.8                                                           10.8           43.8                                                           11.7           49.6                                                           12.7           52.6                                                           13.7           56.3                                                           14.7           61.6                                                           15.9           65.7                                                           17.3           71.3                                                           18.6           76.9                                                           20.1           81.9                                                           21.7           86.5                                                           23.4           90.1                                                           25.2           93.0                                                           29.4           96.5                                                           50.4           99.5                                                           100.5          99.8                                                           1004.0         100.0                                                          ______________________________________                                         *Determined by BJH method                                                

These data show that greater than 50% of the total pore volume iscomprised of pores >8 Å to 20 Å in width (81.9-27.6). Also, the datashow that >80% of the total pore volume is comprised of pores less than20 Å in width. Finally, the data show that >98% of the total pore volumeis comprised of pores less than 50 Å in width.

EXAMPLE 3

A commercially available coconut-based activated carbon product, G210R,was treated as described in the parent application (SN'551). Thegranular product was blended with a solution of KOH at a KOH/carbonratio of 2:1 (dry weight basis). The impregnated carbon was loaded intoa stainless steel retort of an indirect-fired rotary kiln. Thetemperature of the bed was increased from near ambient to 1600° F. overa period of 4 hours. An inert atmosphere in the retort was maintained bya flow of nitrogen gas. The free-flowing, granular product was removedfrom the kiln, cooled to an ambient temperature, and washed with waterat 180° F. The product was dried at 230° F. in a convection oven.

The surface area and pore size distribution data for the precursoractivated carbon and the KOH-activated product, respectively, arerecorded in Table V. These data demonstrate that both the surface areaand the volume of very small pores, i.e., <50 Å width, are substantiallyincreased as a result of performing a second stage of activation of thecoconut-based activated carbon with KOH.

EXAMPLE 4

A commercially available coal-based activated carbon product, F-400 wasactivated with KOH in a manner similar to that described above inExample 3.

The surface area and pore size distribution data for the precursoractivated carbon and the KOH-activated product, respectively, arerecorded in Table V. These data demonstrate that both the surface areaand the volume of very small pores, i.e., <50 Å width, are substantiallyincreased as a result of performing a second stage of activation of thecoal-based activated carbon with KOH.

                  TABLE V                                                         ______________________________________                                                     INFLUENCE OF KOH ACTIVATION                                                   ON PORE VOLUME OF COCONUT                                                     AND COAL-BASED ACTIVATED                                                      CARBON PRODUCTS                                                               Coconut Carbon                                                                           Coal Carbon                                           PRODUCT PROPERTIES                                                                           Precursor                                                                              Product Precursor                                                                            Product                                ______________________________________                                        Surface Area (m.sup.2 g.sup.-1)                                                              1211     1974    991    1528                                   Pore Volume(cc/g)*:                                                           <16Å Width 0.36     0.40    0.28   0.32                                   <20Å Width 0.47     0.65    0.36   0.49                                   <50Å Width 0.57     0.96    0.46   0.74                                   <1000Å Width                                                                             0.59     0.98    0.59   0.87                                   ______________________________________                                         *Determined using BJH method                                             

EXAMPLE 5

A commercially available wood-based activated carbon product, WV-A 1100,was blended with a solution of KOH at a KOH/carbon ratio of 2:1 (dryweight basis). The impregnated carbon was loaded into a stainless steelretort of an indirect-fired rotary kiln. The temperature of the bed wasincreased from near ambient to 1600° F. over a period of 4 hours andheld at 1600° F. for a period of 1 hour. An inert atmosphere in theretort was maintained by a flow of nitrogen gas. The free-flowing,granular product was removed from the kiln, cooled to ambienttemperature, and washed with water at 180° F. The product was dried at230° F. in a convection oven.

The surface area and pore size distribution data for the precursoractivated carbon and the KOH-activated product, respectively, arerecorded in Table VI. These date demonstrate that the volume of verysmall pores, i.e., <50 Å width, is substantially increased as a resultof performing a second stage of activation of the wood-based activatedcarbon with KOH. In particular, the micropore volume, i.e., <20 Å width,is greatly increased by almost 150%.

EXAMPLE 6

A commercially available wood-based activated carbon product, WV-A 1100,was blended with a solution of NaOH at a NaOH/carbon ratio of 2:1 (dryweight basis). The impregnated carbon was loaded into a stainless steelretort of an indirect-fired rotary kiln. The temperature of the bed wasincreased from near ambient to 1600° F. over a period of 4 hours. Aninert atmosphere in the retort was maintained by a flow of nitrogen gas.The free-flowing, granular product was removed from the kiln, cooled toambient temperature, and washed with water at 180° F. in a convectionoven.

The surface area and pore size distribution data for the precursoractivated carbon and the NaOH-activated product, respectively, arerecorded in Table VI. These data demonstrate that volume of very smallpores, i.e., <50 Å width, is substantially increased as a result ofperforming a second stage of activation of the wood-based activatedcarbon with NaOH.

                  TABLE VI                                                        ______________________________________                                                     INFLUENCE OF KOH AND NaOH                                                     ACTIVATION, RESPECTIVELY, ON                                                  PORE VOLUME OF WOOD-BASED                                                     ACTIVATED CARBON                                                              KOH        NaOH                                                  PRODUCT PROPERTIES                                                                           Precursor                                                                              Product Precursor                                                                            Product                                ______________________________________                                        Surface Area (m.sup.2 g.sup.-1)                                                              2294     2312    1556   1917                                   Pore Volume(cc/g)*:                                                           <16Å Width 0.13     0.62    0.06   0.28                                   <20Å Width 0.38     0.91    0.19   0.54                                   <50Å Width 1.24     1.07    0.87   0.94                                   <1000Å Width                                                                             1.59     1.09    1.20   0.98                                   ______________________________________                                         *Determined by BJH method                                                

It is noteworthy also that the granular nature of the precursoressentially is preserved by using the process described herein. This isin marked contrast to the KOH activation processes as previouslydescribed in reference to U.S. Pat. No. 4,082,694, U.S. Pat. No.5,064,805, and U.S. Pat. No. 5,143,889 for the KOH-activation ofcarbonaceous precursors, which produce a low density, small particlesize product that is difficult to handle, both during processing and inuse.

Subsequent activation with KOH of lignocellulose-base, phosphoric acidcarbonized/activated carbons also reduced the total residual phosphatecontent of the carbons. Although this effect was not surprising, themagnitude of the reduction was startling and, indeed, unexpected. Thetotal residual phosphate content of the carbon was reduced from 53% to0.01%. To place this finding in perspective, the lowest total residualphosphate content previously known to be obtained by washing andthermally post-treating a wood-based carbon was about 0.5%. Bearing inmind that some of the surface oxides of wood-based carbons areassociated with the residual phosphate content of the carbon, thesurface chemistry of the KOH-activated carbon may be significantlydifferent from that of the lignocellulose-based carbon activated withphosphoric acid alone. For example, the carbon should be morehydrophobic (less polar), which in itself could favor methaneadsorption.

In summary, subsequent activation of activated an carbon material withKOH at high temperature shifts the pore size distribution of the carbonto a range favorable for methane adsorption. The micropore volume of thecarbon is greatly enhanced to a level not previously obtained. In theexamples cited here, this generally resulted in a deliverable gasstorage capacity of ≧150 v/v at 500 psi. The granular nature of theprecursor is retained following activation with KOH.

While the invention has been described and illustrated herein byreferences to various specific materials, procedures and examples, it isunderstood that the invention is not restricted to the particularmaterials, combination of materials, and procedures selected for thatpurpose. Numerous variations of such details can be employed, as will beappreciated by those skilled in the art.

What is claimed is:
 1. A microporous activated carbon comprising anamount greater than 50% total pore volume of pores in the range ofgreater than 8 Å up to 20 Å in width and an amount greater than 95% ofthe total pore volume of pores up to 50 Å in width, wherein the carbonis derived from lignocellulose material.
 2. The microporous activatedcarbon of claim 1 further comprising an amount greater than 25% of thetotal pore volume of pores of 10 Å to 16 Å in width, an amount greaterthan 70% of the total pore volume of pores less than 20 Å in width, andan amount greater than 98% of the total pore volume of pores less than50 Å in width.
 3. The microporous activated carbon of claim 1 whereinthe lignocellulose material is selected from a member of the groupconsisting of wood chips, sawdust, wood flour, paper, cotton linters,coconut shell, nut shells, and fruit pits.
 4. The microporous activatedcarbon of claim 1 further comprising a total pore volume of at least 0.8cc/g.
 5. The microporous activated carbon of claim 4 further comprisinga total pore volume of at least 1.0 cc/g.